Method and apparatus for molding



Feb. 8, 1949. G. J. kdvAcs 2,460,831

METHOD AND APPARATUS FOR MOLDING Filed Oct. 23, 1944 a INVENTOIVQ.

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Patented Feb. 8, 1949 UNETED STATES PATENT OFFICE 2,460,831 METHOD AND APPARATUS FOR MOLDING George J. Kovacs, Walled Lake, Mich. Application October 23, 1944, Serial No. 559,979

ihe present invention relates to molding thermo-setting materials, and more particularly to a method and apparatus for injection molding, which method consists, broadly, in injecting thermo-setting material or material amenable to such method into a mold through a restricted passage.

Heretoiore, it has been the practice, in injection molding of thermo-setting material to heat the material to at least its plastic temperature in, a plasticizing cylinder and then direct the material through a nozzle into the mold sprue by a piston. The material in the nozzle was heated either by specific heating devices and/or by the conduction of heat from the plasticizing cylinder and particularly heat from the mold to the nozzle. In practice, the temperature of the material in the nozzle would become such as to cause the material to polymerize or, to use an alternate expression, to set up, i. e., to solidify, in the nozzle, and prior to each injection operation it would be necessary to purge the nozzle of this solidified material. Also, when themold was opened and the sprue removed considerable material inside the nozzle would be set up integral with the sprue and would be pulled from inside the nozzle. Thus, the injection molding heretofore practiced was inefficient in the use of materials and with respect to the speed of production of molded parts. Also, in addition to the sources of heat just mentioned, the material, in bein forced into the restricted passageway of the nozzle, would be heated by friction with the walls of the nozzle.

Another objection to injection molding was that the temperature of the material injected into the mold was so close to the setting temperature that the material in the nozzle, sprue and runners of the mold would set up or polymerize throughout its cross-sectional area prior to the polymerization of thematerial in the mold cavities so that, in many instances, additional material could not be fed to the mold to take up shrinkages in the mold and maintain pressure in the mold just prior to and during setting. This condition resulted in imperfect molded parts.

Another method of injection molding has been brought forth wherein it was proposed to raise the temperature of the nozzle considerably above the mold temperature just prior to and during the injection of the material through the nozzle and then cool the nozzle after the injection. In practice, however, the temperature of the nozzle cou d not be reduced rapidly enough to prevent setting up of some material in the nozzle, and a wasteful purging operation was required before 5 Glaims. (Cl. 1830) each injection. Also, since heat was applied to the material in the nozzle, material in the runners and sprue of the mold solidified before sufilcient material and pressure had been applied to the cavities. This condition was further aggravated by the necessarily small orifice of the nozzle wherein setting up of material invariably occurred.

An object of my invention is to provide an apparatus and method of moldin wherein the material, prior to passing into the mold, is con-,- stantly maintained below its setting temperature but at a temperature in which the material flows, thereby completely eliminating setting up of the material in the injecting apparatus.

Another object of my invention is to maintain such differences in temperature between the structure of the injection apparatus comprising the plasticizing cylinder and nozzle and the mold structure, including the sprue and runners of the mold, that setting up or polymerization of the material in the sprue and runners does not completely take place before the setting up of the material in the mold cavities whereby hydraulic transmission of the material through the sprue and runners is maintained until the material in the mold cavities has set. 4

In carrying out my invention, I propose to dissipate heat conducted to the nozzle from the plasticizing cylinder and particularly the mold so that the temperature of the material in the nozzle throughout the length of the latter is at all times maintained below the setting temperature.

I further contemplate controlling the temperature of the material in the nozzle, including the material entering thenozzle passageway, so that the thermo-setting material is maintained in a plastic stage, but always at a temperature below the setting or molding temperature.

Other objects and advantages of my invention will be apparent from the following description of a preferred form of embodiment of the invention, reference being had to the accompanying Fig. 5 is a view inelevation of a sprue'taken from the mold of an apparatus employing the V principle of the present invention.

Referring to the drawings, I have shown a molding apparatus indicated generally at Iii, together with amold cavity, for molding thermosetting material by the injection method of molding. It is to be understood that the apparatus shown is a'preferredform ofthe invention and that other formsoiapparatus may bedevised employing the same principle as contemplatedby myinventionfall of which fall within the scope. of my invention as defined by the appended claims. The apparatus .lfl comprises, inigeneral, a heating or plasticizing chamber, wherein. the, thermo-setting material is preheated to a temperature which renders it;plastic:but:fwithout f causing polymerization thereof. In general,..de-.

I pending on the material'used, this plasticizing cylinder is maintainedat approximately 190 F. A nozzleor-orifice, asin-conventional-practice, is

associated withthe plastieizing cylinderand interconnects theinteriorof the cylinder with the sprue-ofthe mold by contact with the fsprue'bushingv or the-moldstructure, This nozzleis dis-g 'tinguished fromconventionalinjection and similar type nozzles bybeing provided with'an efficient, integral cooling device, and, preferably, there isprovided a thermostatic control-device for maintaining the temperatureofthe nozzle within 'an -optimum rangeformaintaining the thermo setting material p1astic.- Thualprovide means for eiieetively dissipating'heat conductedto the nozzle from the mold, which is' maintained'at a much higher temperature than the'nozzle and plasticizing chamber, and-to also-carry. away heat generated by internal friction and friction by .sliding'conta'ct of the thermo setting material as the thermo-setting material is forced from the plasticizin chamber into and-through the nozzle,

thereby'prevent-ing thetemperature of" the, nozzle and the :plasticiz-ing cylinder from rising to a term perature: 'at which" the therrno-setting material will solidify.

V Anotheradvantage derived from-maintaining this differencein temperature is'jthat aslower rate of travel of the material-through the nozzle can be employed as there is no danger of the material in the inozzle becoming overheated, i. e.

reaching the temperature at which it solidifies and this permitsa nozzle orifice to he used having a 'large f'cross-sectional diameter than certain of those of the prior art; The larger'c'ross sec- V tional diameter of the nozzle permits more rapid and complete 'filling of the mold sprue, runners and cavities, and also materially-increases the size of the piece or. pieces ,which may' be molded inone molding operation, V

In molding systems applying relatively high temperatures to the thermo-settin'g material (either intentionally or. inoidentallyin operation of the systems). prior to the injection of the ma- "terial into the mold, the material in the nozzle, sprue and runners will setup prior to complete setting up of the Imaterial in themold cavities 3.1'1d in some. instances'this occursprior to the complete filling of the mold cavities. This, results in imperfect moldings .due to insurfioient feedin of material through the spruce and runners to the moldsto fill in shrinkagesxandto maintain the required pressure 'untilsetting .np in the cavities has occurred. .By maintaining a substantial difference in temperature between the material in the plasticizi g chamber and nozzle,

and the mold, the material in the nozzle, sprue terial in the mold cavity has set.

. runners.

and runners of the mold does not solidify throughout the cross-sectional area thereof until the ma- During this time pressure and material are applied to the mold through the fluid interiors of the sprue and The relatively large cross sectional area of the nozzleorifice permits continuous application of the requisite pressure for producing high quality molded parts...

, Referring to Fig. 4, asprue of a molded part is shown 'that'was made in a mold by an injection process in which intense. heat was applied to the thermo-setting' material as it passed through the -.nozzle'.. In. Fig. 5,La sprue of a molded part is shown which was made, in the same mold as was used in molding the sprue shownin Fig. 4, but thegmoldingi process vbeing in accordance with my present invention. It will be noted that the part S of the sprue in Fig.4 shrunken compared with the corresponding p'art'of the sprue in Fig. 5. This difference was due to the I inability to supply plastic materialto the interior. f-the-'sp1-ue,

. showninFig; 4; aslthe-entireacross-sectional area of. the material in the nozzle ori-ficesolidified rapidlyand thus additionalmateriat could not be fed to the. sprue or inold' cavities to fill-in shrinkages. This conditionindicates that: the

molded parts are insufiiciently filled-;- On the other hand, the interior'of lthe sprue: shown in Fig. 5 solidifiedslowly relative to the=outer-'portions so that material was transmitted therethrough and filled in all shrinkag'es in thesprues,

' runners and the-molded pieces.

Referring to thes'prues shown in'Fi'g; 4, it will be noticed-that material; indicated at 5!, has adhered to the end of'thes'prue. Thismaterial had solidified inthe nozzleor orifice of the injection' apparatus due to over-heating. The sprue shown in-Fig. 5 shows a cleanbreak' at 5B, which is tthe end of the 'sprue adjacent'to the nozzle of the injection apparatus embodying my invention. The clean break is. aresult of maintaining the temperatureof'the material in' the nozzle below that at which-it sets upby dissipating heat conducted'fr'om-the-mold; Thus, we

have asha'rpbreak or line of demarcatio'n between the polymerizedmaterial in the sprue passage andthe unpolymeriz'ed materia'l in therelatively cool nozzle passage 'Rererring more particularly to-the apparatus 10, the 'plasticizing chamberincludes a cylindrical body H in whicha fluid cooled piston I2 is adapted to be re'ciprocated b'y any suitable mechanism, not shown; whichme'chanism may be an hydraulic motor, forexample. .fihe piston is fluteel-intermediate its ends for permittingescape oi; fine particles of materialfrom between the piston andcylinder walls. Preferably, the piston 12 is cooled duringoperation of the-apparatus, and for this purpose it isboredat l3 and-a tube it extendsinto the boro A cooling ,fiuidsuch as watenis introduced at the left-hand end .of the bore l3 through a .tube Hand passage I5 and is led from the bore I3 through the, tube it through a suitable hose connection not shown. Thermosetting material M'is fed .to the interiorof the cylinder body ll througnan openin it .from

, a'hopper ll,whi ch 'is mounted over, the opening l6." Whenthe piston;l'gisreciprocated in the cylinder it moves to the leit of the opening it and a e ia d ne into t e inder and s mov toward the right by the piston into the bore of a ,cylindrical, body 20,; which is secured. integrally with thQmemberll. Th. body- 20 is provided with a cooling system consisting of an internal passage 2|, through whicha coolant, such as water, may be circulated. The passage 2| is in the form of a spiral and may be formed by cutting a spiral channel about the body 20 and a complementary channel on the interior of the sleeve 24, which is secured over the body 2| by threads, as shown. The water entersthe connection 22, which is connected with one end of the passage 2| and circulates through the passage 2|, then passing from the body 20 through a connection 23. Also, the body 20is adapted to be heated by heatin units indicated at 25, which heating units may be of any suitable electrical resistance material, however, or, it may be heated by any suitable means. In the present embodiment, however, they are resistance elements 26a embedded in ceramic material in the form of bands encircling the sleeve 24 and secured by bolts 26. The temperature of the member 20 is maintained approximately at a predetermined temperature, the particular temperature depending upon the type of thermo-setting material used, and I have shown a thermo-couple element 21, located in the body 20 so that it is responsive to the temperature of the body. The thermo-couple, in the present instance, is part of a system for controlling energizationof the heater elements 26. The control system, however, is not shown, as such systems are known to thoseskilledin the art. Preferably, water is circulated through the body 23 when the body temperature approaches the maximum temperature. This'may be controlled thermostatically by suitable means, not shown. In the present disclosure, the temperature of the body 20 is maintained at approximately 190 F. which is in the optimum temperature range for maintaining the material M plastic but substantially below its setting or polymerizing temperature.

A nozzle 3|! is connected with the body 20 for discharging the plastic material into the sprue of a mold 40. The nozzle 3|] includes a thin-walled neck 3| threaded at the outer end and a cupshaped jacket 32 is threaded on the neck for directing a coolant thereabout. It is to be understood that this jacket could be welded or otherwise joined to the nozzle for the purpose stated. The orifice 35 through the neck 3| is shown tapering outwardly. The degree of taper may be more or less than that shown or the orifice may have a uniform diameter, or it may fiare,-' but, preferably, the walls leading from the plasticizing chamber to the entrance of the orifice taper gradually for reducing friction of the material on the walls adjacent to the nozzle entrance to a minimum. An inlet connection 33 is connected in an opening formed in the jacket 32 so that a cooling fluid, in the present instance water, may be led to the jacket 32 and the water is discharged from the jacket through a connection 34. Preferably, a thermostatic control valve, indicated diagrammatically at 36, is placed in the discharge of the jacket 32 and is responsive to the temperature of the water about the nozzle for restricting passage of water from the jacket as the temperature falls toward the minimum temperature at which the material is plastic and increasing the flow when the temperature rises toward the setting up temperature of the material. It is essential to the successful practice of my inventions that the cooling device, in the present embodiment the jacket 32 and water circulating connections, be so designed that it can dissipate heat from the nozzle structure rapidly enough to prevent the material in the nozzle from setting. It will be'noted that the jacket extends adjacent to the entrance to the nozzle from the chamber so that heat generated by the friction of the material passing into the nozzle passageway can be carried away. This heat would otherwise accumulate at the entrance to the nozzle and cause setting up of the material at this point.

. The mold structure 43 which is formed of'two parts 4| and 42 has a sprue bushing 42a in the part 4| for directing the thermo-setting material to the runners 43, formed in the chamber 42. The mold 40 is provided with six mold cavities .44, the cavities in this instance being illustrated as cubes, although they may be of any desired form, depending upon the shape of the article desired.

A sprue puller and knock-out rod is provided, which is operated by suitable mechanism, after the mold part 42 has been separated from part 4| following a molding operation, for pulling thev sprue from the spruebushing 42a and then for knocking the sprue and its integral runners from the part 42. Also, knock-out rods may be provided for removing the molded pieces from the cavities 44, but since such knockout rods are well known they have not been shown. It is to be understood that for the sake of clearness, the various elements for supporting the mold and its parts and the mechanism for operating the sprue puller 45 are not shown, as they may be of conventional design.

The mold 40 is maintained at a temperature at which the thermo-setting material will be polymerized and this temperature is considerably above that at which the body 20 and the nozzle 3| are maintained. In the present instance, the temperature is maintained at approximately 420 F. The parts 4| and 42 have electrical resistance elements 46 embedded therein'for heating the mold, although any other suitable heating means may be used, and the temperature of the mold is controlled by a suitable control mechanism for the heating elements, which system includes a thermo-couple 41 embedded in the part 42 of the mold. The thermo-couple 41 affects the control system in a manner well known in the art and therefore this control system is not shown;

In the operation of the apparatus IE, the thermo-setting material M is placed in the hopper IT in a powdered or granulated condition and the piston H. is operated to move the material into the bore of the body 20. The material is heated in the body 20 to a temperature at which it becomes plastic. The sprue bushing 42a of the mold 40 is maintained in contact with the nozzle and in alignment with the nozzle orifice. The part 42 of the mold is closed on part 4|, as shown I in the drawings, and the piston I2 is then actuated to force the plasticized material through the into the mold cavities 44. The relatively higher temperature of the mold structure causes polymerization of the thermo-setting material to take place, which polymerization will occur first adjacent to the walls of the mold. The interior of the sprue and runners remain fluid for an interval and provide transmission of material and pressure to the cavities until the material in the cavities has hardened. The piston acts upon the material 'during the polymerization of the material in the mold for maintaining the required pressure in the mold cavities and to fill in any shrinkages. After polymerization has taken place in the mold the force of piston |2 acting on the'material is relieved and the mold part 42 isremoved from ithemar-t :41, :the :latter eing maintained *tactiwithithe nozzle;plt'-'willbefotmdzth V tosmaintaining': the, temperature in tthesnezzle i -below :the. setting up' temperature got the imamrialilvl a. cleanzbreak will. beieilectedqbetween:the end of. thessprue and the material in, thQanezz-l-e.

- This is illustrated in mg. :5 :1 v een .;alluded to. hereinbef ore. :Afte :113h8 enrue anersrand cavities 101 the :mold'it? have rbeenemptied, another. molding operati' diatelyperformed}inatheesame manner without :the; necessity oi purging thexinjection apnaratus '7 i-of hardened material as ';has :been -;c-u stemarlly :necessary in injection molding. 71-35 V thatw successive molding operations :can be 1 ditions causing hardening of .:injection apparatus.

' ,ed articles are produce aamaei runformed rapidly because oi the eliminationioficenthe material :in the Thus, Ilhave'yprovided a novel mechanism and thermo-setting materials. By,preventinggthe:aecumulation of heat in the nozzle and pl'asticizing chamberandby holding thenozzleand plasth .cizing chamber at an; optimum temperature ;at 3. all times, considerable saving cfgthernioasetting material is effected by ,the elimination .Qf -.the usual purging operations, and more perfeetmoldheretofore possible.

Although-I; have shown only oneiorm :o f- 'the ,"embodiment of my inventionit is ito be understoodpthat other forms might :be adopted, ll

- -comingjwithin" the scope of the claims'qwhich ;follow., V p "I-claim:

' 1. The method :of continuously .injedtingla thermosetting material into a mold heated at least at the polymerizing temperature 10f said material which comprises 'pressure feeding .SEid "material into a'chamber, heating said lmaterial 7 V in said chamber toa plasticizingtemperature -below thesetting temperature and cooling said material toitsp lasticizing temperature whenever the temperature of the chamber :rises above the plasticizing temperature of the materialitherein,

"'Tpressure feeding said material fromsai'd chamber irlto and throughan ejecting nozzlein the torm 2. In the method of continuously injecting a jtherinosetting material into a mold heatedzat ]least at the polymerizing temperature ofvsaid mw te'rial, including the pressure feeding oi-saidunater'ial into and'throug'h a chamber, the steps i which compriselcooling said material to fa plasticiz'ing temperature'below the-setting temperature 1' whenever the temperature o'f'the chamberarises above the plasticizing temperature of the mai terial therein, pressure feeding saidmateri'al from said chamber into and through an'ejectingnozz'le inthe form 'of a substantially restrictedipa'ssage whereby to further densify the materialiiniits V I "*passagethrough-said nozzle, removing heatfrom 175 aerial in'the nozzlepassageand excessheat caused d with-greatenspeed than ,3

a '8 ,lsaid; mozzle whenever --the temperature of the :nozzle erises abovethe plasticizi-ng temperature of lsaid material-fwhereby to I remove excess accumu- 7 lating heate caused by densification and friction .ofthe material in the nozzlapassageand by heat lleakage thereto irom tthe heatedf mold, and injecting =;said a-densified plasticized. material, at its ,gplasticizingztemperature fromtsaid nozzle into ,said heated,:,material-receiving .mo1d.

- '53. ;In an apparatus forgthe :continuous moldin @of -thermosetting (material, including a heated, material-receiving mold maintained j at least at the ;polymerizing temperature of .said; material, --;a.ch amber ,-.for receiving and densifying the -thermosetting Y, material and for heating said. ma-

terial up to litsplasticizing temperature-to trans- ;formasaid material to its thermally, non-setting 1state, ra pressure plunger atone end-of said chamber for forcing-said material through said .chamberand thereby densifysaid material, an

ejectingnozzle-structure the-form of a substantial y restricteapassage immediately assofcia-ted with the other end of said chamber .for gf'urther densifying the material in its passage from the chamber through the nozzle, heattransferring means associated with said nozzle including accoling passage disposed adjacent said :noz zle passage and adapted -to provide for the ,flowof a coolant fluid therethrough, a valve for regulating the rate :of flow of thecoolant fluid into said cool ingpassage and regulating means controlling said valve whenever the temperature VciLt-he nozzle risesiabove'the plasticizing temperature-of said material whereby to remove excess accumulating heat caused by densification and yfri'ctionof the ,material in the nozzle passage and .excess heat caused ,by leakage thereto from the heated mold, said heated, materialreceivingmold l-beingin registration withthe ejecting end'of said knozzle passa-ge for receiving the densified, plasticized material at its plasticizing temperature rfromzthe nozzle passage. v V

4; an apparatus for the continuous molding of thermosetting -'-rnateri-al, including a heated, Qmaterial-receiving mold maintained at least at the polymerizing temperature of said material, a

chamber iorgreceiving and densifying the thermosettingmater-ial and forheating said-material up to its -plasticizing temperature to transform said .materialto its -thermally,-non-setting state, heat- ;transferring means for coolingsaid-chamberdown -,to:the plasticizingtemperatureofthe material in said {chamber whenever the temperature of said :chamber rises :above-said plasticizing temperature,- a pressurev plunger-at 011$ end of a said chamfiber; for ,forcing said materialthrough said-cham- 1 :berandithereby-densify saidmateriaLan ejecting :nozzle structure in the form of a substantially wssociated'with'said nozzle includinga cooling passageddisposedadjacent said nozzle passage and adapted: to provideiorthe flow ofa coolant fluid ;therethrough, ayalve for regulating the rate of iflow ofthe coolant-fluidinto saidcooling passage 1 amdsregulating means, responsive to the temperaiture'of the-nozzlefor controlling said valve when- "ever the temperature-of the nozzle rises above the plas'ticizing temperature of said material whereby tofiremove excessaccumulating heat .caused by densification and friction of the maby leakage thereto from the heated mold, said heated, material-receiving mold being in registration with the ejecting: end of said nozzle passage for receiving the densified, plasticized material at its plasticizing temperature from the nozzle passage.

5. The combination set forth in claim 3, wherein the :cooling passage is in the form of an annular jacket disposed around said nozzle passage.

GEORGE J. KOVACS.

REFERENCES CITED The following references are of record in the file of this patent:

5 UNITED STATES PATENTS Number Name Date 7 1,993,942 Novotny Mar. 12, 1935 2,090,489 Sommerfeld Aug. 17, 1937 10 2,338,691 Tucker Jan. 4, 1944 Shaw Mar. 14, 1944 

